Female engaging surface fastener having a backing and method of making same

ABSTRACT

A method for producing an extruded sheet material wherein a polymeric material is formed into a sheet and a variety of materials are incorporated into the extruded material prior to hardening. The sheet materials produced incorporate, either sheet, filament or particulate matter onto either side of the finished product, allowing for great variability in the finished product.

BACKGROUND OF THE INVENTION

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/275,485 entitled “Female Engaging Surface FastenerHaving A Backing And Method For Making Same,” filed on Mar. 14, 2001.

[0002] The present invention relates to the field of surface fastenersand their production. In particular, the present invention relates tosurface fasteners that are manufactured from polymeric resins, havefemale engaging members bonded thereto and, additionally, include asecond element bonded to the surface fastener.

[0003] Surface engaging fasteners are well know in the art and arecommonly found to be of a hook and loop configuration. These are largelyfound to be manufactured according to two wellknown processes. The moretraditional method provides for the weaving of both the hook element andthe loop element. The loop element is usually woven from a multifilamentyarn, creating a patterned web with raised protrusions forming the loopelements. These loops may then be napped, in a separate procedure toseparate the multifilaments and increase the number of loops, which maybe held by the hook. The hook is commonly also woven through a similarweaving procedure, but due to peel and shear demands, must beconstructed with a higher denier fiber. The hook fiber is commonlyconstructed from a monofilament, and after weaving, results in a similarpatterned web with raised protrusions. After weaving of the hookelement, the raised, woven protrusions are incapable of binding to theloop element as a result of the weaving procedure. In order for thewoven monofilament to actually function as a hook, it must undergo aslitting procedure where each raised protrusion is cut, thereby allowingthe monofilament hook to engage at least one or more of the nappedmultifilaments of the loop element. The hook tips may also be melted toproduce a mushroom shape that engages another mushroom hook element.Such a conventional device and method is illustrated in U.S. Pat. No.3,009,235, entitled “Separable Fastening Device.”

[0004] A second method of producing hook and loop surface fastenersinvolves extruding a plate-like sheet element and imparting the desiredhook profile unto the extruded material. This method allows for theproduction of a hook element, similar to the above woven hook but atreduced manufacturing costs. A further improvement in the manufacture ofhook and loop elements is illustrated in U.S. Pat. No. 5,974,635,entitled “Female Engaging Member of Surface Fastener and Method ofManufacturing the Same.” In this process, a series of multifilamentyarns are arranged in parallel relationship to each other and at regularintervals. The parallel yarns are then converged with a flat plate-likesheet member being fed from a roll at a constant rate. The finishedproduct allows for the production of a loop element through a partialextrusion process through the incorporation of a multifilament ormonofilament yarn product to the flat plate-like sheet member.

[0005] Another method of producing an extruded hook product is disclosedin U.S. Pat. No. 5,744,080, entitled “Laminated Hook Fastener.” Thelaminated product is manufactured through the extrusion of plasticmaterial onto a roll having hook forming cavities on its surface. Asecond plastic material is further extruded at an interface between aforming roll and a second strip carried by a backing roll to form afinished article having extruded loop material on one surface and asheet material on its second surface. This product requires the use of aplastic bonding material to join the extruded hook layer to the addedsheet layer.

[0006] Although the prior art has shown the woven and extrudedmanufacture of hook and loop elements along with the plastic bonding ofsheet backing materials to extruded hook elements, there is still a needfor the manufacture of an extruded loop fastening element having backingsurfaces that may include a variety of materials, either in sheet orparticulate form.

SUMMARY OF THE INVENTION

[0007] In accordance with these and other objects of the invention, abrief summary of the present invention is presented. Somesimplifications and omission maybe made in the following summary, whichis intended to highlight and introduce some aspects of the presentinvention, but not to limit its scope. Detailed descriptions of apreferred exemplary embodiment adequate to allow those of ordinary skillin the art to make and use the invention concepts will follow in latersections.

[0008] It is therefore a primary object of the present invention toprovide a non-woven product having fastening loop elements on onesurface along with a second material on a second surface.

[0009] It is a further object of the present invention to provide for amethod of efficiently producing such a product through a manufacturingprocess that allows for the production of a dual sided, nonwoven articleincluding fastening loop elements on one surface along with a secondmaterial on a second surface.

[0010] It is still another object of the present invention to accomplishthe above-stated objects by utilizing a method and apparatus, which issimple in design and use, and efficient to manufacture.

[0011] According to a broad aspect of the present invention, a surfacefastening device is disclosed which includes a sheet like structurehaving a first surface with a material selected from yarn, thread, sheetmaterial and particulate material bonded thereto and a second surfacewith a material selected from yarn, thread, sheet material andparticulate material also bonded thereto.

[0012] According to another broad aspect of the present invention, amethod is disclosed for producing a surface fastening device. The methodincludes the extrusion of a sheet like structure having the ability tobind a material prior to hardening. A material selected from yarn,thread, sheet to material, particulate material and combinations thereofis brought into contact with one face of the extruded sheet prior to itshardening. A second material selected from yarn, thread, sheet material,particulate material and combinations thereof is also brought intocontact with a second face of the extruded sheet prior to hardening andthe sheet is allowed to harden.

[0013] The foregoing objects and advantages of the invention areillustrative of those that can be achieved by the present invention andare not intended to be exhaustive or limiting of the possible advantageswhich can be realized. Thus, these and other objects and advantages ofthe invention will be apparent from the description herein or can belearned from practicing the invention, both as embodied herein, or asmodified in view of any variation which may be apparent to those skilledin the art. Accordingly, the present invention resides in the novelmethods, arrangements, combinations and improvements herein shown anddescribed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a cross sectional view schematically showing oneembodiment of a production apparatus of the present invention.

[0015]FIG. 2 is a cross sectional view schematically showing oneembodiment of a production apparatus of the present invention.

[0016]FIG. 3 is a cross sectional view schematically showing oneembodiment of a production apparatus of the present invention.

[0017]FIG. 4 is a cross sectional view schematically showing oneembodiment of a production apparatus of the present invention.

[0018]FIG. 5 is a perspective view of the surface fastening producthaving an attached backing.

[0019]FIG. 6 is a perspective view of an additional embodiment of thesurface fastening product having an attached backing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Referring now to the drawings, in which like numerals refer tolike components or steps, there is disclosed in FIG. 1 broad aspects ofa preferred embodiment of the present invention. FIG. 1 discloses ageneral arrangement of an apparatus for use in the production of oneembodiment of the present invention system. A polymeric material 11,such as polyvinyl chloride (PVC), or polypropylene, is found in itsmolten state inside a holding vessel 12. A spinning roll 14 is found inclose proximity to a discharge nozzle 13. A first material dispenser 15,housing a sheet material 16 is located proximal to the spinning roll 14.Multiple material dispensers 17, each housing a respective filamentmaterial 18 are also located in proximity to the spinning roll 14. Inuse, the sheet material 16 and the filament material 18 are fed into thespinning roll 14. As the molten material 19 is extruded through thedischarge nozzle 13, it assumes the shape given to it by the spinningroll 14 but does not immediately harden. During this hardening period,the material 11 remains tacky. As the molten material 19 is discharged,it is brought into contact with the sheet material 16 on one face andfilament material 18 on its opposite face. The molten material 19,having the sheet material 16 and the filament material 18 bonded toeither face, is then discharged at a point in the spinning roll 14,opposite the discharge nozzle 13. The finished product 10 includes asheet like structure including a sheet like material such as paper,abrasive paper, non-woven fabric, woven and knitted textiles, scrims,netting, plastic film, extruded male fastening members, molded malefastening members and metallic screening on one face, an intermediatepolymeric material such as PVC, and a filament material, such as yarn orthread on the opposite face of the polymeric material.

[0021]FIG. 2 shows a general arrangement of an apparatus for use in theproduction of another embodiment of the present invention. Again, apolymeric material 21, is found in a molten state inside a holdingvessel 22. A spinning roll 24 is found in close proximity to a dischargenozzle 23. A first material dispenser 25 housing an abrasive sheetmaterial 26, such as sandpaper, is located in proximity to the spinningroll 24. A second material dispenser 27, housing a second sheetmaterial, such as a web of extruded or molded hook surface fasteners 28is also located in proximity to the spinning roll 24. In use, theabrasive sheet material 26 and the second sheet material 28 are fed intothe spinning roll 24. As the molten material 29 is extruded through thedischarge nozzle 23, the molten material 29 assumes the shape given toit by the spinning roll 24 but does not immediately harden. During thishardening period, the material 11 remains tacky. As the molten material29 is discharged, it is brought into contact with the abrasive sheetmaterial 26 on one face and second sheet material 28 on its oppositeface. The molten material 29 having the abrasive sheet material 26 andthe second sheet material 28 bonded to either face is then discharged ata point in the spinning roll 24, opposite the discharge nozzle 23. Thefinished product 20 is a sheet like structure including a sheet likematerial such as paper, abrasive paper, non-woven fabric, woven andknitted textiles, scrims, netting, plastic film, extruded male fasteningmembers, molded male fastening members and metallic screening on oneface, an intermediate polymeric material such as PVC, and a second sheetlike material, such as paper, abrasive paper, non-woven fabric, wovenand knitted textiles, scrims, netting, plastic film, extruded malefastening members, molded male fastening members and metallic screeningon the opposite face of the polymeric material.

[0022]FIG. 3 shows a general arrangement of an apparatus for use in theproduction of a further embodiment of the present invention. Again, apolymeric material 31, is found in a molten state inside a holdingvessel 32. A spinning roll 34 is found in close proximity to a dischargenozzle 33. Multiple filament dispensers 35 housing a filament material36, such as yarn, are located in proximity to the spinning roll 34. Asecond set of multiple filament dispensers 37, housing a filamentmaterial 38, such as yarn, are also located in proximity to the spinningroll 34. In use, the first set of filament material 36 and the secondset of filament material 38 are fed into the spinning roll 34. As themolten material 39 is extruded through the discharge nozzle 33, itassumes the shape given to it by the spinning roll 34 but does notimmediately harden. During this hardening period, the material 31remains tacky. As the molten material 39 is discharged, it is broughtinto contact with the first set of filament material 36 on one face andthe second set of filament material 38 on its opposite face. The moltenmaterial 39 having the first set of filament material 36 and the secondset of filament material 38 bonded to either face is then discharged ata point in the spinning roll 34, opposite the discharge nozzle 33. Thefinished product 30 forms a sheet like structure including a set offilament material such as yarn or thread on one face, an intermediatepolymeric material such as PVC, and a second set of filament material,such as yarn or thread on the opposite face of the polymeric material.

[0023]FIG. 4 shows a general arrangement of an apparatus for use in theproduction of yet a further embodiment of the present invention. Again,a polymeric material 41, is found in a molten state inside a holdingvessel 42. A spinning roll 44 is found in close proximity to a dischargenozzle 43. Multiple filament dispensers 45 housing a filament material46, such as yarn, are located in proximity to the spinning roll 44. Aparticulate matter dispenser 47, housing a particulate material 48, suchas abrasive particles, is also located in proximity to the spinning roll44. In use, the filament material 46 and the particulate material 48 arefed into the spinning roll 44. As the molten material 49 is extrudedthrough the discharge nozzle 43, it assumes the shape given to it by thespinning roll 44 but does not immediately harden. During this hardeningperiod, the material 49 remains tacky. As the molten material 49 isdischarged, it is brought into contact with the filament material 46 onone face and the particulate material 48 on its opposite face. Themolten material 49 having a filament material 46 and particulatematerial 48 bonded to either face is then discharged at a point in thespinning roll 44 a, opposite the discharge nozzle 43. The finishedproduct 40 includes a sheet like structure including a set of filamentmaterial such as yarn or thread on one face, an intermediate polymericmaterial such as PVC, and an abrasive particulate material, such asdiamond particles on the opposite face of the polymeric material.

[0024] The finished articles 10 and 40, described with reference toFIGS. 1 and 4 above, may be used for creating a sheet like articlehaving an abrasive surface and an opposite female engaging surface. Suchan article may be utilized in the construction industry in applicationssuch as circular or vibration driven sanders. For example, a disk sandermay be fitted with hook elements on the face of the disk. The femaleengaging face of the finished articles 10 and 40 having bound filamentmaterial may then be engaged with the hook material of the disk sander.The material may then be utilized until the abrasive qualities of thearticles 10 and 40 are diminished. The article may then be easilyremoved and a replacement article 10 or 40 engaged. An article 20, asdescribed with reference to FIG. 2, may also be used for a similarapplication when the first sheet material 26 includes an abrasivecontaining sheet material and the second sheet material 27 includes asheet material such as a web of extruded or molded hook surfacefasteners. Such a product would function in a similar way to thearticles 10 and 40 described with reference to FIGS. 1 and 4 but thedisk sander would included a loop element that engages second sheetmaterial 27 having hook surface fasteners. The finished article 30described in FIG. 3 may be used in applications where a double-sidedloop structure is desired.

[0025] Turning now to FIG. 5, an embodiment of the finished product isshown. The product 100 includes a sheet-like substrate 102. Pile-shapedengaging elements 104 are bonded to one side of the substrate 102.Pile-shaped engaging elements 104 are made from a plurality of filaments108 which are wound around core threads 106. The winding filament 108has a longer length than the circumference of the core thread 106 orthreads thus allowing loops of filaments 108 to extend from the corethreads 106. The process of forming the pile-shaped engaging elements104 is known in the art and is shown in U.S. Pat. No. 5,974,635, whichis herein incorporated by reference. Therefore no further discussion ofthe process is necessary.

[0026] The sheet-like substrate 102 also includes a backing material110. The number of possible backing materials 110 is unlimited. Sandpaper, abrasive grit, adhesive paper products, paper products, paperproducts including indicia or advertising, woven textile products,non-woven textile products, etc. can all be used as the backing material110.

[0027]FIG. 6 discloses an additional embodiment of the presentinvention. The product 100 includes a sheet-like substrate 102. Thesubstrate 102 includes rows of elevated portions 112. Each pile-shapedengaging element 104 meets and is bonded to an upper part of theelevated portions 112. This provides additional strength to the bondbetween the pile-shaped engaging element 104 and the substrate 102.Again the sheet-like substrate 102 also includes a backing material 110.The number of possible backing materials 110 is unlimited. Sand paper,abrasive grit, adhesive paper products, paper products, paper productsincluding indicia or advertising, woven textile products, non-woventextile products, etc. can all be used as the backing material 110.

[0028] Although the present invention has been described in detail withparticular reference to preferred embodiments thereof, it should beunderstood that the invention is capable of other different embodiments,and its details are capable of modifications in various obviousrespects. As is readily apparent to those skilled in the art, variationsand modifications can be affected while remaining within the spirit andscope of the invention. Accordingly, the foregoing disclosure,description, and FIGS. are for illustrative purposes only, and do not inany way limit the invention, which is defined only by the claims.

What is claimed is:
 1. A product having a surface fastener, comprising:a sheet-like substrate having a first surface and a second surface; aplurality of rows of pile-shaped engaging elements bonded to the firstsurface of the sheet-like substrate and having a plurality of filamentswound around a core thread such that the winding of each filament woundaround the core thread has a length greater than that of the outerperiphery of the core thread; and a material bonded to the secondsurface of the substrate.
 2. The product of claim 1, wherein thematerial is sand paper.
 3. The product of claim 1, wherein the materialis abrasive grit.
 4. The product of claim 1, wherein the material is asheet of male engaging members complementary to the pile-shaped engagingelements.
 5. The product of claim 1, wherein the material is a woventextile product.
 6. The product of claim 1, wherein the material isnon-woven textile product.
 7. The product of claim 1, wherein thematerial is a sheet having an adhesive portion.
 8. The product of claim1, wherein the material is a sheet of a paper product.
 9. The product ofclaim 1, wherein the first surface of the sheet-like substrate includesa plurality of rows of elevated portions and wherein each pile-shapedengaging element is bonded with top faces of the elevated portions. 10.The product of claim 9, wherein the material is sand paper.
 11. Theproduct of claim 9, wherein the material is a sheet of male engagingmembers complementary to the pile-shaped engaging elements.
 12. Theproduct of claim 9, wherein the material is a woven textile product. 13.The product of claim 9, wherein the material is non-woven textileproduct.
 14. The product of claim 9, wherein the material is a sheethaving an adhesive portion.
 15. The product of claim 9, wherein thematerial is a sheet of a paper product.
 16. A method of making product,comprising: continuously extruding a polymeric material onto a spinningroller such that the polymeric material is formed into a sheet having afirst surface and a second surface; providing a plurality of pile-shapedengaging elements having a plurality of filaments wound around a corethread such that the winding of each filament wound around the corethread has a length greater than that of the outer periphery of the corethread; feeding the pile-shaped engaging elements into engagement alongthe first surface of the polymeric material; providing a sheet ofmaterial; and feeding the sheet of material into engagement along thesecond surface of the polymeric material.
 17. The method of claim 16,wherein the sheet of material is sand paper.
 18. The method of claim 16,wherein the sheet of material is a sheet of male engaging memberscomplementary to the pile-shaped engaging elements.
 19. The method ofclaim 16, wherein the sheet of material is a woven textile product. 20.The method of claim 16, wherein the sheet of material is a non-woventextile product.
 21. The method of claim 16, wherein the polymericmaterial is extruded such that the first surface includes rows ofelevated portions and wherein each piled-shaped engaging elements is fedalong the elevated portion.
 22. The method of claim 16, wherein thesheet of material is sand paper.
 23. A method of making product,comprising: continuously extruding a polymeric material onto a spinningroller such that the polymeric material is formed into a sheet having afirst surface and a second surface; providing a plurality of pile-shapedengaging elements having a plurality of filaments wound around a corethread such that the winding of each filament wound around the corethread has a length greater than that of the outer periphery of the corethread; feeding the pile-shaped engaging elements into engagement alongthe first surface of the polymeric material; providing a supply ofabrasive grit; and feeding the abrasive grit into engagement along thesecond surface of the polymeric material.
 24. The method of claim 23,wherein the polymeric material is extruded such that the first surfaceincludes rows of elevated portions and wherein each piled-shapedengaging elements is fed along the elevated portion.